Hyundai – Santa Fe 2013

Kia– Sorento 2014 (3rd Row)

Kia Optima 2013

1st Row

2nd Row

3rd Row

Before

After Relocation of all Trim to Foam assemblies to a central location -Allowed removal of trapped labor and head count reductions to be made-Subassemblies built in sequence-Reduced the amount of defects due to reducing the choices operators on line have to make, now they choose the next available subassembly-Enhanced Visual Management with better 5S, clear flow of material-Control excess WIP

More examples of kitting subassemblies

From this picture you can see one of your 5S stations that store the cleaning supplies

These are WIP carts for transport of Back Frame subassemblies, color coded for better Visual Management. Again these subassemblies are built in sequence (JIT)

Track subassemblies are kitted to the line. Change was required due to the original objective of this project which was to increase the width of the aisle to allow for fork lift traffic

A wider view of the overall line from which you can see some improvements made

Back frame subassembly originally required 3 operators per shift, we were able to reduce to 1 per shiftAfter -New layout -Rearrangement of parts based on the frequency of use we were able to reduce to 1 operator-Taking one part of one option of seat and moving the assembly line

New location of all cushion and back trim to foam sub assemblies for the plant. Allowed for many benefits including reducing the required Indirect Labor team members due to the newer closer location of the trim warehouse

More examples of VM and dedicated WIP carts

New wider aisle

Old Kit box, parts could be placed anywhere and often would arrive at the line with incorrect or missing parts, causing throughput issues

New Kit box with a cut out and specified location for all parts, position of part within kit totes are based on the order of picking from the warehouse

CEO & the Board on the final plant tour